Automated System and Method for Smoothing Wrinkled Material

ABSTRACT

A method and apparatus for smoothing a material having wrinkles. The material is positioned on a vacuum table having a group of segments. A smoothing device is moved across a surface of the material to form a substantially smooth section of the material. A vacuum is progressively applied to a portion of the group of segments in the vacuum table corresponding to the substantially smooth section of the material to pull the substantially smooth section of the material against the vacuum table.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of and claims the benefit of U.S.patent application Ser. No. 14/453,670, entitled “Automated System andMethod for Smoothing Wrinkled Material,” attorney docket number14-0077-US-NP, filed Aug. 7, 2014 and is incorporated herein byreference in its entirety.

BACKGROUND INFORMATION 1. Field

The present disclosure relates generally to manufacturing and, inparticular, to materials used in manufacturing. Still more particularly,the present disclosure relates to an automated system and method forsmoothing wrinkled material used in manufacturing.

2. Background

Layers of material are used for various applications. For example,without limitation, layers of material may be used to form structures,seal openings, rework surfaces, or for some other suitable purpose.

In some instances, two or more layers of material may be positionedrelative to one another and joined together. For example, the layers ofmaterial may be cured, bonded, fastened, or attached to one another toform a structure. These layers of material may take the form of sheets.

A sheet of material may have various thicknesses, depending on the typeand use of the material. For instance, a sheet of material may have athickness ranging from about a fraction of a nanometer to a centimeteror more.

When working with sheets of material, eliminating wrinkles and folds isdesirable. These wrinkles may inhibit bonding, predispose the materialto tearing, or otherwise cause more inconsistencies than desired duringuse of the sheet. For example, if a sheet of material is notsubstantially smooth, a structure formed from the sheet of material maybe formed with out of tolerance voids, porosity, or otherinconsistencies. As another example, when reworking a surface, awrinkled sheet of material may result in poor adhesion to the surface.

To reduce the risk of inconsistencies, a sheet of material may besmoothed prior to being used for its intended purpose. Some existingsolutions require human operators to manually smooth each sheet ofmaterial. Oftentimes, these human operators smooth each sheet ofmaterial using their hands or handheld tools. This process takescountless labor hours to complete.

In addition, the human operators must be highly trained to smooth thesheet of material without tearing or otherwise altering the structuralproperties of the material. Finding highly skilled human operators maybe more difficult and time-consuming than desired. Consequently,manufacturing processes using the material may cost more than desired.Therefore, it would be desirable to have a method and apparatus thattake into account at least some of the issues discussed above, as wellas other possible issues. Specifically, it is desirable to find a methodand apparatus to more quickly smooth wrinkled material.

SUMMARY

In one illustrative embodiment, a method for smoothing a material havingwrinkles is provided. The material is positioned on a vacuum tablehaving a group of segments. A smoothing device is moved across a surfaceof the material to form a substantially smooth section of the material.A vacuum is progressively applied to a portion of the group of segmentsin the vacuum table corresponding to the substantially smooth section ofthe material to pull the substantially smooth section of the materialagainst the vacuum table.

In another illustrative embodiment, an apparatus comprises a vacuumtable, a smoothing device, and a vacuum system. The vacuum table has agroup of segments. A material having wrinkles is positioned on thevacuum table. The smoothing device moves across a surface of thematerial to form a substantially smooth section of the material. Thevacuum system progressively applies a vacuum to a portion of the groupof segments in the vacuum table to pull the substantially smooth sectionof the material against the vacuum table.

In yet another illustrative example, a method for smoothing a materialhaving wrinkles using an automated smoothing system is presented. Thematerial having wrinkles is positioned on a vacuum table. The vacuumtable has a group of segments. The material is clamped to the vacuumtable using a clamping system. A smoothing device is translated across asurface of the material using a first movement system to form asubstantially smooth section of the material. A vacuum is applied to asegment in the group of segments in the vacuum table immediately afterthe smoothing device translates across the surface of the materialcorresponding to the segment.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of a manufacturing environment in accordancewith an illustrative embodiment;

FIG. 2 is an illustration of an automated smoothing system in accordancewith an illustrative embodiment;

FIG. 3 is an illustration of a vacuum table in accordance with anillustrative embodiment;

FIG. 4 is an illustration of a side view of an automated smoothingsystem in accordance with an illustrative embodiment;

FIG. 5 is an illustration of a bottom view of a vacuum table inaccordance with an illustrative embodiment;

FIG. 6 is an illustration of a smoothing device including a brush inaccordance with an illustrative embodiment;

FIG. 7 is an illustration of a front view of a brush system and acutting system in accordance with an illustrative embodiment;

FIGS. 8-16 are illustrations of a process for smoothing a material inaccordance with an illustrative embodiment;

FIG. 17 is an illustration of a block diagram of a manufacturingenvironment in accordance with an illustrative embodiment;

FIG. 18 is an illustration of a flowchart of a process for smoothing amaterial having wrinkles in accordance with an illustrative embodiment;

FIG. 19 is an illustration of a more-detailed flowchart of a process forsmoothing a material having wrinkles in accordance with an illustrativeembodiment;

FIG. 20 is an illustration of a flowchart of a process for transportinga substantially smooth sheet of material in accordance with anillustrative embodiment; and

FIG. 21 is an illustration of a flowchart of a process for designing astructure in accordance with an illustrative embodiment.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or moredifferent considerations. For example, the illustrative embodimentsrecognize and take into account that it may be desirable to have anautomated process for smoothing a wrinkled material before using it forvarious manufacturing processes. The illustrative embodiments recognizeand take into account that using human operators to manually smooth thewrinkled material takes more time and resources than desired. In somecases, skilled workers are not available to perform such manualsmoothing processes, which slows down manufacturing processes that needsmoothed material.

The illustrative embodiments further recognize and take into accountthat it may be desirable to have an automated system for smoothingmaterials that is flexible based on the type and thickness of materialbeing smoothed. For example, the illustrative embodiments recognize andtake into account that different thicknesses and types of material mayhave different considerations during a smoothing process.

Moreover, the illustrative embodiments recognize and take into accountthat it may be desirable to have an automated system that can smooth asheet of material without tearing the material. The illustrativeembodiments recognize and take into account that as the thickness of thematerial decreases, the fragility of the material increases. As aresult, smoothing thinner materials is particularly challenging andtime-consuming.

Thus, the illustrative embodiments provide an automated system andmethod for smoothing a material having wrinkles. This material may bereferred to as “material having wrinkles,” “wrinkled material,” a“wrinkled sheet of material,” or a “wrinkled layer of material,”throughout the illustrative examples.

In an illustrative example, the material is positioned on a vacuum tablehaving a group of segments. A smoothing device is moved across a surfaceof the material to form a substantially smooth section of the material.A vacuum is progressively applied to a portion of the group of segmentscorresponding to the substantially smooth section of the material topull the substantially smooth section of the material against the vacuumtable. Each segment is activated immediately after the smoothing devicepasses over the surface of the material corresponding to that particularsegment.

Turning next to FIG. 1, an illustration of a manufacturing environmentis depicted in accordance with an illustrative embodiment. In thisdepicted example, manufacturing environment 100 is an environment inwhich automated smoothing system 102 is used to smooth material 103having wrinkles 104.

As depicted, material 103 may include a number of layers of material inthis illustrative example. As used herein, a “number of” items is one ormore items. Thus, a number of layers is one or more layers. In thisparticular example, material 103 is a single layer of material.

Material 103 also may have various thicknesses. In some cases, material103 may be a thin film material. When material 103 is a thin filmmaterial, material 103 may have a thickness of about a fraction ofnanometer to about several hundred micrometers. In other illustrativeexamples, material 103 has a thickness outside this range.

In this illustrative example, material 103 may comprise a number ofdifferent types of materials. For example, material 103 may comprise atleast one of a metal, a polymer, or some other suitable type ofmaterial.

As used herein, the phrase “at least one of,” when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used and only one of the items in the list may be needed. Theitem may be a particular object, thing, or category. In other words, “atleast one of” means any combination of items or number of items may beused from the list, but not all of the items in the list may berequired.

For example, “at least one of item A, item B, and item C” may mean itemA; item A and item B; item B; item A, item B, and item C; or item B anditem C. In some cases, “at least one of item A, item B, and item C” maymean, for example, without limitation, two of item A, one of item B, andten of item C; four of item B and seven of item C; or some othersuitable combination.

In this depicted example, material 103 has a rectangular shape withsurface 107. Material 103 may have other shapes in other illustrativeexamples. For instance, material 103 may have a square shape, an ovalshape, a triangular shape, an irregular shape, a hexagonal shape, orvarious other shapes. Automated smoothing system 102 may smooth material103 regardless of its shape.

Material 103 may be stored on roll 106. In an illustrative example,material 103 may be unrolled from roll 106 with surface 107 facingupwards. In other instances, material 103 may take the form of a sheetthat is positioned relative to automated smoothing system 102 in someother manner, depending on the particular implementation.

In this depicted example, automated smoothing system 102 forms asubstantially smooth sheet of material 103. A number of differentcomponents in automated smoothing system 102 are used to smooth material103 in a desired manner.

After the smoothing process is completed, the material may be referredto as a “smoothed sheet of material,” “smoothed material,” a“substantially smooth sheet of material,” and so forth. In each case,wrinkles 104 and undesired folds in the material have been reduced oreliminated by automated smoothing system 102.

In this illustrative example, manufacturing environment 100 alsoincludes transport device 108, human operator 109, and controller 110.In this illustrative example, transport device 108 picks up and movesthe substantially smooth sheet of material 103 from one location toanother location.

Transport device 108 takes the form of a robotic device in thisillustrative example. Arm 112 with end effector 114 of transport device108 is used to transport material 103. In this manner, transport device108 transports the material to another location for further processing.

In other instances, transport device 108 may take a different form thanshown in this view. For example, transport device 108 may include atleast one of a human operator, a manual device, a gantry system, or someother suitable tool configured to pick up and move material from onelocation to another location while maintaining the substantially smoothcharacter of the material.

Human operator 109 is present in manufacturing environment 100 in thisillustrative example. However, human operator 109 is not manuallyperforming smoothing operations on material 103. Instead, the smoothingprocess is entirely automated in this illustrative example. In otherwords, material 103 is smoothed without intervention from human operator109. In some instances, human operator 109 may perform other operationssimultaneously with automated smoothing system 102 and transport device108, but the presence of human operator 109 is unnecessary in thisillustrative example.

As illustrated, controller 110 may control operation of at least one ofautomated smoothing system 102 or transport device 108. Controller 110may communicate with an on-board controller on either device (not shownin this view) to coordinate operation of automated smoothing system 102,transport device 108, or both. This coordinated operation may includepositioning, feedback, instructions, and other control processes priorto, during, and after smoothing occurs. For instance, concurrentprocessing may be employed.

Once material 103 is smoothed within selected tolerances, transportdevice 108 quickly transports the smoothed sheet out of the work area.Almost immediately, automated smoothing system 102 may begin smoothinganother portion of material 103 having wrinkles. For example, more ofmaterial 103 may be unrolled from roll 106. As a result, smoothing andtransport of the material may be completed more efficiently than withsome currently used systems.

With reference next to FIG. 2, an illustration of an automated smoothingsystem is depicted in accordance with an illustrative embodiment. Inthis depicted example, an enlarged view of automated smoothing system102 from FIG. 1 is shown.

Automated smoothing system 102 includes a number of different componentsin this illustrative example. In particular, automated smoothing system102 includes vacuum table 200, smoothing device 202, clamping system204, sensor system 206, cutting system 208, unrolling tool 210, andvision system 211.

As illustrated, material 103 is positioned on vacuum table 200. Vacuumtable 200 is a platform that provides structural support for material103 as material 103 is smoothed. A vacuum system (not shown in thisview) is used to pull material 103 against vacuum table 200 immediatelyafter smoothing device 202 moves over surface 107 of material 103corresponding to a vacuum segment in vacuum table 200. Although vacuumtable 200 is shown as a flat structure, vacuum table 200 may be curvedin some illustrative examples.

Vacuum table 200 may include porous material 213 in this illustrativeexample. When material 103 is positioned for a smoothing operation,porous material 213 is positioned directly under material 103. Porousmaterial 213 is a material comprising voids, or pores. The materialselected for porous material 213 allows air to travel through the voidssuch that a vacuum can be applied to material 103. When a vacuum isapplied, material 103 is pulled against porous material 213 in vacuumtable 200.

Additionally, in some illustrative examples, air may be blown throughporous material 213 to separate material 103 from vacuum table 200 oncesmoothed. In still other illustrative examples, porous material 213 maybe a type of material that contains holes or other manufacturedopenings. In some illustrative examples, porous material 213 may be aporous paper material. In some other examples, porous material 213 maybe a woven polymeric material. In yet other examples, porous material213 may be a metallic material with holes throughout.

In this illustrative example, smoothing device 202 includes a number offeatures used to remove wrinkles 104 from surface 107 of material 103.For example, smoothing device 202 may include a brush, an air knife, orother suitable devices to remove wrinkles 104 from material 103.

Smoothing device 202 moves back and forth in the direction of arrow 212.As an example, smoothing device 202 may move across surface 107 ofmaterial 103 from one part of material 103 to another part to form asubstantially smooth section of material 103. In one illustrativeexample, smoothing device 202 may move across surface 107 of material103 from a clamped end of material 103 to a free end of material 103 toform a substantially smooth section of material 103. The clamped end maybe a part of material 103 held in place by clamping system 204.

The number of features of smoothing device 202 touches surface 107 as itmoves. For example, when the number of features is an air knife, airfrom the air knife may touch surface 107 as smoothing device 202 moves.When the features are a brush, the brush may touch surface 107 assmoothing device 202 moves. The force provided by and movement ofsmoothing device 202 along surface 107 removes wrinkles 104 frommaterial 103.

In this depicted example, smoothing device 202 also moves up and down inthe direction of arrow 214. After the smoothing process is completed,smoothing device 202 may be lifted and retracted back to a startingposition to smooth the next wrinkled section of material 103 positionedon vacuum table 200.

Clamping system 204 applies a force against material 103 to holdmaterial 103 in place. As depicted, clamping system 204 includes anumber of devices to clamp material 103 to vacuum table 200 and holdmaterial 103 against vacuum table 200 while smoothing device 202 movesacross surface 107 of material 103 to remove wrinkles 104. In thismanner, clamping system 204 temporarily secures material 103 asoperations are performed by components in automated smoothing system102.

Clamping system 204 also may move in the direction of arrow 212, arrow214, or both. In some cases, an additional clamping system may bepresent in automated smoothing system 102.

Sensor system 206 identifies a position of smoothing device 202 relativeto surface 107 of material 103. The position may be identified usingcoordinates of a reference coordinate system for manufacturingenvironment 100.

Sensor system 206 comprises a number of components to identify theposition of smoothing device 202 relative to surface 107 of material103. In this illustrative example, sensor system 206 includes a set ofsensors. As used herein, a “set of” items is one or more items. In thisillustrative example, a set of sensors is one or more sensors. In thisdepicted example, a sensor in sensor system 206 may be selected from oneof a laser sensor, a camera, a transducer, an ultrasonic sensor, or someother suitable type of position sensor.

As shown in this view, sensor system 206 moves as smoothing device 202moves. In other illustrative examples, sensor system 206 may not movewith smoothing device 202, depending on the particular implementation.Sensor system 206 provides position feedback to a controller (not shownin this view) that controls operation of the components in automatedsmoothing system 102. Sensor system 206 also may provide feedback tocontroller 110 shown in FIG. 1. Vacuum table 200, smoothing device 202,or both may be operated by the controller based on the position ofsmoothing device 202 determined by sensor system 206.

Cutting system 208 may separate sheets of material 103 from roll 106.Cutting system 208 includes a number of components to separate material103 from roll 106. For example, without limitation, cutting system 208may include a blade, scissors, a laser cutter, or some other suitabletype of cutting mechanism. The components within cutting system 208 movein the direction of arrow 212, arrow 214, or both to cut the material.

Unrolling tool 210 may be used to unroll a desired amount of materialonto vacuum table 200. In some illustrative examples, unrolling tool 210may unroll material 103 onto vacuum table 200 from roll 106.Alternatively, human operator 109 in FIG. 1 may unroll the material.

In an illustrative example, unrolling tool 210 may include components totemporarily attach to one end of material 103. For example, withoutlimitation, unrolling tool 210 may grab the free end of material 103using a vacuum source and pull material 103 across vacuum table 200 inthe direction of arrow 215. Unrolling tool 210 pulls material 103 outonto vacuum table 200 until a desired amount of material 103 ispositioned on vacuum table 200. Unrolling tool 210 then may deactivatethe vacuum and place the free end of material 103 down on vacuum table200. In one illustrative example, a puff of air separates material 103from unrolling tool 210.

Material 103 may be unrolled by rotating roll 106 in the direction ofarrow 218 in this illustrative example. In other examples, roll 106 maybe absent from automated smoothing system 102. In such a case, material103 may be precut and positioned on vacuum table 200 by human operator109, transport device 108, or another component.

In still other illustrative examples, additional rolling devices may bepresent in automated smoothing system 102. For example, when material103 includes a backing, the backing may be removed as material 103 isunrolled onto vacuum table 200. This backing may be rolled up on anotherroll mechanism for easy disposal.

As depicted, vision system 211 is positioned above vacuum table 200.Vision system 211 includes a number of components to identify a level ofwrinkle removal for material 103. For example, without limitation,vision system 211 may include a camera or other suitable device todetermine the extent to which wrinkles have been removed from material103. In other words, vision system 211 is used to determine whether adesired smoothness for material 103 has been reached.

In addition, vision system 211 may generate feedback during thesmoothing process. This feedback can be used to adjust the movement,pressure, or other parameters of smoothing device 202 as desired.

In some cases, additional vision systems may be positioned relative tovacuum table 200. Further, vision system 211 may have other positionsand orientations relative to vacuum table 200 than shown in this view.For instance, vision system 211 may be attached to other structureswithin automated smoothing system 102 and move accordingly. In stillother illustrative examples, vision system 211 may rotate, translate, orotherwise move about a number of axes to establish a desired line ofsight.

In FIG. 3, an illustration of a vacuum table is depicted in accordancewith an illustrative embodiment. An enlarged view of vacuum table 200from FIG. 2 is shown in this figure.

In this depicted example, porous material 213 in vacuum table 200 hasbeen removed to show different components within vacuum table 200. Inthis illustrative example, vacuum table 200 is divided into group ofsegments 300. As used here, a “group of” items is two or more items.Thus, group of segments 300 comprises two or more segments.

Group of segments 300 takes the form of hollow compartments throughwhich air can travel. Each segment may be referred to as a vacuumsegment in this illustrative example.

Each segment in group of segments 300 is separated from one another. Inthis manner, a vacuum may be pulled on one segment without affectingother segments in group of segments 300. As a result, different segmentsin group of segments 300 may be activated at different times,progressively, sequentially, simultaneously, or in some other manner.

In an illustrative example, each sequential segment may be activated inthe direction of arrow 302 as smoothing device 202 moves along surface107 of material 103. Any portion of group of segments 300 may be activeat the same time. When a segment is “activated,” that segment is undervacuum. Activating each segment in this manner, immediately aftersmoothing device 202 moves across surface 107 corresponding to thatsegment, reduces or eliminates wrinkles 104 from material 103.

A controller (not shown in this view) is used to control operation ofeach segment in group of segments 300 individually. In this illustrativeexample, the controller may switch on and off a vacuum generatorattached to each segment. The vacuum generator may be attached to eachsegment using vacuum lines (not shown in this view) connected to holes304 in group of segments 300. One or more of holes 304 correspond to asingle segment in group of segments 300. As depicted, holes 304 may bein the sides of group of segments 300. However, in other illustrativeexamples, holes 304 may be located in any suitable location such thatthe vacuum lines may be connected to holes 304. For example, holes 304may be located at the bottom of segments 300.

With reference now to FIG. 4, an illustration of a side view of anautomated smoothing system is depicted in accordance with anillustrative embodiment. In this illustration, a side view of automatedsmoothing system 102 is shown in the direction of lines 4-4 in FIG. 2.

Vacuum system 400 and controller 402 in automated smoothing system 102are seen in this view. Vacuum system 400 comprises a number of devicesto apply a vacuum to vacuum table 200. In particular, vacuum system 400progressively applies a vacuum to a portion of group of segments 300 invacuum table 200 shown in FIG. 3 to pull material 103 against vacuumtable 200.

In this illustrative example, “progressively” refers to a process thatproceeds in increments. In other words, vacuum system 400 may turn ondifferent segments in group of segments 300 in vacuum table 200 inincrements, one right after another.

In an illustrative example, vacuum system 400 may pull a vacuum on apoint along material 103 before, during, or after smoothing device 202moves across that point. However, applying a vacuum to a segment ingroup of segments 300 in vacuum table 200 shown in FIG. 3 immediatelyafter smoothing device 202 moves over that particular segment may beoptimal. In other words, applying a vacuum to a point along material 103immediately after smoothing device moves across that point of material103 may be optimal. Progressively pulling material 103 against vacuumtable 200 holds the smooth sections of material 103 flat, keeping adesired level of smoothness within the material without formingundesired inconsistencies in the material, tearing the material, and soforth.

Vacuum system 400 may comprise a number of different components. Forexample, without limitation, vacuum system 400 includes vacuumgenerators 404 and vacuum lines 406. Vacuum generators 404 provide thevacuum to pull material 103 against vacuum table 200. Vacuum lines 406connect vacuum generators 404 to different segments in group of segments300 in vacuum table 200 shown in FIG. 3. Each of vacuum lines 406 may bein fluid communication with one segment in group of segments 300 in thisillustrative example.

As illustrated, controller 402 is an electrical device to activatevacuum system 400 to pull a vacuum on vacuum table 200. Specifically,controller 402 activates different segments in vacuum table 200 based onthe position of smoothing device 202 relative to surface 107 of material103.

In this illustrative example, controller 402 may be implemented insoftware, hardware, firmware, or a combination thereof. When software isused, the operations performed by controller 402 may be implementedusing, for example, without limitation, program code configured to runon a processor unit. When firmware is used, the operations performed bycontroller 402 may be implemented using, for example, withoutlimitation, program code and data and stored in persistent memory to runon a processor unit.

When hardware is employed, the hardware may include one or more circuitsthat operate to perform the operations in controller 402. Depending onthe implementation, the hardware may take the form of a switch, acircuit system, an integrated circuit, an application specificintegrated circuit (ASIC), a programmable logic device, or some othersuitable type of hardware device configured to perform any number ofoperations.

A programmable logic device may be configured to perform certainoperations. The device may be permanently configured to perform theseoperations or may be reconfigurable. A programmable logic device maytake the form of, for example, without limitation, a programmable logicarray, a programmable array logic, a field programmable logic array, afield programmable gate array, or some other type of programmablehardware device.

In some illustrative examples, the operations, processes, or bothperformed by controller 402 may be performed using organic componentsintegrated with inorganic components. In some cases, the operations,processes, or both may be performed entirely of organic components,excluding a human being. As one illustrative example, circuits inorganic semiconductors may be used to perform these operations,processes, or both. The aforementioned examples also may be applied tocontroller 110, as shown in FIG. 1.

Controller 402, controller 110, or both, may be implemented in acomputer system. The computer system may comprise one or more computers.When more than one computer is present in the computer system, thosecomputers may be in communication with one another over a communicationsmedium such as a network. In this illustrative example, controller 402and controller 110 may communicate with one another. In other examples,at least one of controller 402 or controller 110 may be implemented as achip or device other than a computer.

Automated smoothing system 102 is also equipped with blower 410. Blower410 is configured to blow ionized air (not shown in this view) onmaterial 103.

Blower 410 is located on clamping system 204 in this example. In otherillustrative examples, blower 410 may be located on unrolling tool 210or smoothing device 202. Additional blowers also may be used to directionized air onto surface 107 of material 103.

In this illustrative example, ionized air may be used to reduce staticelectricity on and around material 103. It may be desirable to reducestatic electricity such that material 103 does not stick to vacuum table200 in an undesired manner. For instance, ionized air may be used toprevent the material from sticking to vacuum table 200 when the vacuumis turned off and the material is ready for transport by transportdevice 108.

Turning next to FIG. 5, an illustration of a bottom view of a vacuumtable is depicted in accordance with an illustrative embodiment. In thisdepicted example, a bottom view of vacuum table 200 is shown in thedirection of lines 5-5 in FIG. 4.

As shown, vacuum lines 406 are connected to ports 500 extending fromvacuum table 200. Each of vacuum lines 406 is connected to one of ports500 in this illustrative example. A segment in group of segments 300 inFIG. 3 may include one or more of ports 500.

Referring to FIG. 6, an illustration of a smoothing device including abrush is depicted in accordance with an illustrative embodiment. In thisfigure, an enlarged view of smoothing device 202 from FIG. 2 is shown.

As depicted, smoothing device 202 includes brush 600, first movementsystem 602, and second movement system 604. In this illustrativeexample, brush 600 moves across surface 107 of material 103 shown inFIG. 1 using at least one of first movement system 602 and secondmovement system 604.

In this depicted example, brush 600 is an object configured to removewrinkles 104 from material 103. Brush 600 has bristles 606. Bristles 606may be helically wound bristles in this illustrative example. In otherwords, bristles 606 are twisted about brush 600 in a repeating spiralpattern. This configuration of brush 600 with helically wound bristles606 forms a cylindrical brush.

In other illustrative examples, different shapes and configurations forbrush 600 may be used. For example, brush 600 may comprise straightbristles that hang from an elongate member and brush over surface 107 ofmaterial 103. In another illustrative example, the entire surface ofbrush 600 may be covered in bristles 606, instead of having a helicallywound portion of bristles 606.

The size and spacing between helically wound bristles 606 can bemodified to smooth material 103 in a desired manner. For instance, thehelix may be wound tightly such that each winding of bristles 606 ispositioned next to one another. In another example, the helix may bewound such that each winding has a desired amount of space in between.In this manner, the pitch of bristles 606 is modified to reduce wrinkles104 as desired. The pitch of bristles 606 is the width of one completehelix turn, measured parallel to the axis of brush 600.

Additionally, the stiffness, material, or length selected for bristles606 may be modified based on the type of material being smoothed. Insome cases, softer bristles 606 may be needed. As an example, whensmoothing fragile material, softer bristles 606 may be used. Conversely,when more rigid and less fragile material is being smoothed, differentbristles 606 may be used. In this manner, brush 600, with bristles 606,is replaceable and can be exchanged with another brush and bristleconfiguration, depending on the particular implementation. Brush 600also may be exchanged with an air knife or other smoothing device inother implementations.

In an illustrative example, first movement system 602 includescomponents configured to translate smoothing device 202 across surface107 of material 103. First movement system 602 may include at least oneof a track system, wheels, a pneumatic device, a hydraulic device, amotor, casters, or other suitable components.

In this illustrative example, first movement system 602 is a tracksystem connected to vacuum table 200. First movement system 602 isconfigured to move smoothing device 202 back and forth over material 103in the direction of arrow 212.

As illustrated, second movement system 604 comprises componentsconfigured to rotate brush 600 having helically wound bristles 606 assmoothing device 202 translates across surface 107 of material 103.Second movement system 604 may include a motor and other suitablecomponents configured to rotate brush 600. In this illustrative example,second movement system 604 rotates brush 600 over material 103 in thedirection of arrow 610. This rotational movement, combined with thetranslation of smoothing device 202 pushes wrinkles 104 out of material103. With the bristles 606 helically wound as depicted, wrinkles willmove wrinkles 104 from the inside to the outside. Specifically, thecombination of helically wound bristles 606, the rotational movement inthe direction of arrow 610 and the translational movement in thedirection of arrow 212, may smooth material 103 by pushing wrinkles 104from about the center of material 103 outwards to the edges of material103. Other patterns of bristles 606 or other movements may move wrinkles104 in different directions.

In this illustrative example, a third movement system (not shown in thisview) also may be used to position brush 600 relative to surface 107 ofmaterial 103. As an example, the third movement system moves brush 600toward surface 107 and away from surface 107 in the direction of arrow214. Through the use of first movement system 602, second movementsystem 604, and optionally a third movement system, precise positioningand operation of smoothing device 202 is achieved.

In FIG. 7, an illustration of a front view of a brush system and acutting system is depicted in accordance with an illustrativeembodiment. In this view, smoothing device 202 is shown in the directionof lines 7-7 in FIG. 6. In this view, the helically wound configurationof bristles 606 is seen in more detail.

In addition, cutting system 208 with cutter 700 and track system 702 isshown. Cutter 700 is an object configured to cut through material 103shown in FIG. 1. Cutter 700 may take the form of a blade, a knife,scissors, a laser cutter, or some other suitable object. Track system702 moves cutter 700 back and forth in the direction of arrow 704 to cutmaterial 103.

In this illustrative example, cutting system 208 is attached to movementsystem 706. Movement system 706 comprises at least one of a motor, atrack system, a pulley, or some other suitable device configured to movecutting system 208 up and down in the direction of arrow 214. In thismanner, cutting system 208 can be accurately positioned relative to thesurface of a material to cut through material 103.

FIGS. 8-16 illustrate a process for smoothing material 103 in accordancewith an illustrative embodiment. In FIGS. 8-16, material 103 is smoothedand cut using automated smoothing system 102.

With reference to FIG. 8, unrolling tool 210 has unrolled material 103on roll 106 onto vacuum table 200. Unrolling tool 210 picked up the freeend of material 103 and moved in the direction of arrow 215 to unrollmaterial 103. Material 103 rolled out onto vacuum table 200 has wrinkles104 throughout. After the material is rolled out onto vacuum table 200,clamping system 204 moves downward in the direction of arrow 800 toclamp down material 103.

In FIG. 9, unrolling tool 210 has released material 103 and continued tomove in the direction of arrow 215 shown in FIG. 2 to a retractedposition. Once unrolling tool 210 is retracted, smoothing device 202moves upward in the direction of arrow 900, over unrolling tool 210, andtoward clamping system 204 in the direction of arrow 902 to a startingposition.

Smoothing device 202 moves over material 103 to the starting positionwithout touching surface 107 in this illustrative example. In otherwords, smoothing device 202 is lifted and then retracted. After reachingthe starting position, smoothing device 202 moves downward in thedirection of arrow 800 to touch surface 107 of material 103.

FIG. 10 shows smoothing device 202 in the starting position. In thestarting position, bristles 606 touch surface 107 of material 103.Smoothing device 202 may now move in the direction of arrow 215 tosmooth material 103. As smoothing device 202 moves, bristles 606 arerotated to push out wrinkles 104 from the material.

In this illustrative example, sensor system 206 provides continuousposition feedback to controller 402 shown in FIG. 4. This positionfeedback is used to activate different segments in group of segments 300in vacuum table 200 shown in FIG. 3. For instance, a vacuum is appliedto a first segment of vacuum table 200 nearest clamping system 204immediately after smoothing device 202 passes over that segment. Avacuum may then be applied to a second segment of vacuum table 200adjacent to the first segment, and so on, to progressively pull asubstantially smooth section of material 103 against vacuum table 200after smoothing device 202 has removed wrinkles 104 from that section.Specifically, a vacuum may be pulled through porous material 213 toprogressively pull the substantially smooth section of material 103against porous material 213 of vacuum table 200.

Referring to FIG. 11, smoothing device 202 has moved approximatelyhalfway across surface 107 of material 103 as different segments invacuum table 200 are activated. Substantially smooth section 1100 ofmaterial 103 has been formed. In other words, automated smoothing system102 has reduced or eliminated wrinkles 104 from material 103 to withinselected tolerances within substantially smooth section 1100. Visionsystem 211 may monitor the progress of smoothing device 202 in removingwrinkles 104.

FIG. 12 shows smoothing device 202 after reaching the end point. A puffof air (not shown) may be used to prevent folds from occurring at theedge of material 103 as smoothing device 202 reaches the edge.

In some cases, an inspection of substantially smooth section 1100 ofmaterial 103 may be completed to determine whether wrinkles 104 havebeen removed in a desired manner. For instance, surface 107 may beinspected using vision system 211 to determine whether it is smoothedwithin selected tolerances. The process shown in FIGS. 8-12 may berepeated if additional smoothing of that sheet of material 103 isrequired. Otherwise, substantially smooth section 1100 of material 103is cut into a sheet.

Referring next to FIG. 13, smoothing system 202 has moved to the otherside of unrolling tool 210. The vacuum is still applied to group ofsegments 300 to hold the smooth material against porous material 213 ofvacuum table 200.

Cutting system 208 is positioned relative to material 103 at a desiredlocation for a cut. For example, cutter 700 is moved to the location forthe cut. Specifically, cutting system 208 has moved outward in thedirection of arrow 215 from its stored position. Cutting system 208moves downward in the direction of arrow 800 to place cutter 700 onsurface 107 of substantially smooth section 1100 of material 103.

In FIG. 14, cutting system 208 has moved downward in the direction ofarrow 800 using movement system 706. Cutter 700 touches surface 107 ofmaterial 103. Cutter 700 now begins to move in direction 1400 usingtrack system 702 to cut through material 103. Cutter 700 cuts material103 to form a substantially smooth sheet of material from material 103.As depicted, the substantially smooth sheet comprises substantiallysmooth section 1100. Cutter 700 cuts substantially smooth section 1100of material 103 away from roll 106. In this manner, the smoothed sheetof material 103 is completely separated from roll 106 in thisillustrative example.

In this illustrative example, cutter 700 moves within groove 1402 invacuum table 200 to cut material 103. Groove 1402 may serve as a guidefor accurate cutting.

With reference to FIG. 15, substantially smooth sheet 1500 of material103 has been formed. The smoothing and cutting process now may becomplete. Substantially smooth sheet 1500 of material 103 is ready to bemoved to a different location for further processing.

Turning now to FIG. 16, transport device 108 with end effector 114 ispositioned over substantially smooth sheet 1500 of material 103. Endeffector 114 may move downward in the direction of arrow 800 to apply aforce to surface 107 of substantially smooth sheet 1500 of material 103.

Transport device 108 then pulls a vacuum on surface 107 to transfersubstantially smooth sheet 1500 of material 103 to end effector 114 fortransport. Vacuum table 200 is deactivated. A puff of air fromunderneath substantially smooth sheet 1500 of material 103 (not shown)may aid in transferring substantially smooth sheet 1500 of material 103to end effector 114.

Although the illustrations in FIGS. 8-16 show material 103 beingunrolled from roll 106, precut sheets of wrinkled material 103 may beused instead. In such a case, the sheet is positioned on vacuum table200, clamped down using clamping system 204, and processed as describedwith reference to FIGS. 9-16. In this manner, automated smoothing system102 provides versatility in its use with various types, shapes, orthicknesses of material.

In FIG. 17, an illustration of a block diagram of a manufacturingenvironment is depicted in accordance with an illustrative embodiment.In this illustrative example, manufacturing environment 1700 is depictedin block form to illustrate different components for one or moreillustrative embodiments that may be used to manufacture structuresusing sheets of material.

In this illustrative example, design 1702 may be generated for structure1704. Structure 1704 may be selected from one of, for example, acomposite part, a repair patch, a metal part, a panel, a compartment, acontrol surface, a structural member, a housing, or some other suitablepart.

Structure 1704 may be used in platform 1705. Platform 1705 may be, forexample, without limitation, a mobile platform, a stationary platform, aland-based structure, an aquatic-based structure, and a space-basedstructure. More specifically, the platform may be a surface ship, atank, a personnel carrier, a train, an aircraft, a spacecraft, a spacestation, a satellite, a submarine, an automobile, a power plant, abridge, a dam, a house, a manufacturing facility, a building, and othersuitable platforms.

Design 1702 may be, for example, a computer-aided design model or someother model that may be used to control manufacturing system 1706 tofabricate structure 1704. In this illustrative example, design 1702 maybe generated using designer 1708.

Designer 1708 may be implemented in software, hardware, firmware or acombination of thereof. When software is used, the operations performedby designer 1708 may be implemented in program code configured to run ona processor unit. When firmware is used, the operations performed bydesigner 1708 may be implemented in program code and data and stored inpersistent memory to run on a processor unit. When hardware is employed,the hardware may include circuits that operate to perform the operationsin designer 1708.

As depicted, designer 1708 may be implemented in computer system 1710.Computer system 1710 may be one or more computers. When more than onecomputer is present in computer system 1710, those computers maycommunicate with each other using a communications medium such as anetwork.

In the illustrative example, design 1702 for structure 1704 is generatedusing input 1712. Input 1712 may include, for example, design 1714,desired performance parameters 1716, and other suitable types of input.Input 1712 may originate from various sources. For example, input 1712may be received from at least one of a file, a human operator, acomputer-aided design, a specification, or some other suitable source.

In the illustrative example, design 1714 may be a computer-aided designmodel of structure 1704. In the depicted example, design 1714 mayinclude dimensions 1719 for structure 1704. Dimensions 1719 may include,for example, at least one of cross-sectional shapes, diameter, length,or other suitable parameters that may be used to describe structure1704.

Desired performance parameters 1716 are for the performance of structure1704. In this illustrative example, desired performance parameters 1716may be selected from at least one of a load, a coefficient of thermalexpansion, toughness, fracture resistance, stiffness, strength,visibility, detectability, electromagnetic effect protection properties,or other suitable performance parameters that may be desirable forstructure 1704.

With input 1712, designer 1708 generates design 1702. For example,designer 1708 may generate parameters 1718 for material 1720 used toform structure 1704.

As depicted, parameters 1718 may be selected for each sheet 1721 ofmaterial 1720 used to form structure 1704. For example, parameters 1718may include at least one of dimensions 1724, materials 1726, desiredsmoothness 1728, or other suitable parameters. Material 1720 haswrinkles 1729 in this example.

Parameters 1718 may include dimensions 1724 of each sheet 1721 ofmaterial 1720 used to form structure 1704. Dimensions 1724 may include athickness of each sheet 1721 of material 1720. For instance, parameters1718 may indicate that material 1720 is a thin film material.

In the illustrative examples, materials 1726 may describe componentmaterials within material 1720. For example, materials 1726 may beselected from at least one of a metal, a metal alloy, carbon fiber, aceramic, a polymer, or some other suitable material.

In an illustrative example, desired smoothness 1728 describes thecondition of sheet 1721 of material 1720 needed to manufacture structure1704. Desired smoothness 1728 may refer to an amount of wrinkles 1729,or folds, allowed to be present in sheet 1721 of material 1720. Desiredsmoothness 1728 also may indicate other characteristics for the surfaceof sheet 1721 of material 1720. From parameters 1718, instructions formanufacturing system 1706 are generated.

In the illustrative example, manufacturing system 1706 may use design1702 to manufacture structure 1704. Additionally, manufacturing system1706 also removes wrinkles 1729 material 1720. After the wrinkles 1729are removed, and material 1720 has been cut to form sheet 1721 withdesired dimensions 1724, sheet 1721 of material 1720 is used to formstructure 1704.

Manufacturing system 1706 may include a number of different types ofcomponents. For example, manufacturing system 1706 may include automatedsmoothing system 1730 and material transport system 1732. In thisillustrative example, automated smoothing system 1730 and materialtransport system 1732 include various devices. These devices may becomputer-controlled. In some cases, these devices may be operated orobserved by a human operator. Manufacturing environment 100 in FIG. 1may be a physical implementation of manufacturing system 1706 of FIG.17.

As depicted, automated smoothing system 1730 includes various componentsused to form substantially smooth sheet 1734 of material 1720. Automatedsmoothing system 102 shown in FIGS. 1-16 is an example of a physicalimplementation for automated smoothing system 1730 shown in block formin this figure.

Automated smoothing system 1730 utilizes a segmented vacuum table andsmoothing device to progressively remove wrinkles 1729 from material1720. Material 1720 is clamped down while automated smoothing system1730 removes wrinkles 1729. As the smoothing device moves over material1720, wrinkles 1729 are removed to form substantially smooth section1735 of material 1720. This section gets larger as the smoothing deviceprogresses over material 1720. Segments in the vacuum table areactivated to pull substantially smooth section 1735 of material 1720against the vacuum table to keep it flat. Specifically, a vacuum may bepulled through a porous material over the segments in the vacuum tableto pull substantially smooth section 1735 of material 1720 against theporous material of the vacuum table. More and more segments areactivated as more of material 1720 is smoothed. These segments remainactivated until a desired amount of material 1720 is smoothed.

As illustrated, material transport system 1732 may be a system used totransport sheet 1721 of material 1720 after being smoothed. In otherwords, after forming substantially smooth sheet 1734 of material 1720,material transport system 1732 may transport substantially smooth sheet1734. Transport device 108 shown in FIG. 1 is an example of a physicalimplementation for material transport system 1732 shown in block form inthis figure.

In this illustrative example, material transport system 1732 may be arobotic device, a conveyor system, a human operator, an elevator, amagnetic system, or other suitable device. In some cases, manufacturingsystem 1706 may include additional tools to cut sheet 1721 of material1720, trim structure 1704, bond components, cure components, or performother processes.

The illustration of manufacturing environment 1700 in FIG. 17 is notmeant to imply physical or architectural limitations to the manner inwhich an illustrative embodiment may be implemented. Other components inaddition to or in place of the ones illustrated may be used. Somecomponents may be unnecessary. Also, the blocks are presented toillustrate some functional components. One or more of these blocks maybe combined, divided, or combined and divided into different blocks whenimplemented in an illustrative embodiment.

For example, substantially smooth sheet 1734 of material 1720 can beused for other purposes other than forming structure 1704. As anexample, substantially smooth sheet 1734 of material 1720 can be placedover a surface to seal the surface. In other illustrative examples,substantially smooth sheet 1734 of material 1720 may provide acorrosive-resistant coating for a structure. In yet another illustrativeexample, substantially smooth sheet 1734 of material 1720 may be used toform dielectric layers for electronic devices. In still anotherillustrative example, substantially smooth sheet 1734 of material 1720may be used to rework a damaged structure.

The different components shown in FIGS. 1-16 may be combined withcomponents in FIG. 17, used with components in FIG. 17, or a combinationof the two. Additionally, some of the components in FIGS. 1-16 may beillustrative examples of how components shown in block form in FIG. 17can be implemented as physical structures.

With reference now to FIG. 18, an illustration of a flowchart of aprocess for smoothing a material having wrinkles is depicted inaccordance with an illustrative embodiment. The process shown in FIG. 18may be implemented using automated smoothing system 1730 to smoothmaterial 1720 in FIG. 17. The process shown in FIG. 18 may beimplemented using automated smoothing system 102 shown in FIGS. 1-16 tosmooth material 103 having wrinkles 104.

The process begins by positioning a material having wrinkles on a vacuumtable having a group of segments (operation 1800). The material havingwrinkles may be precut and placed on the vacuum table as a sheet in anillustrative example. In another illustrative example, the materialhaving wrinkles may be unrolled from a roll.

Next, the process moves a smoothing device across a surface of thematerial to form a substantially smooth section of the material(operation 1802). The smoothing device may include at least one of abrush and an air knife.

The process progressively applies a vacuum to a portion of the group ofsegments in the vacuum table corresponding to the substantially smoothsection of the material to pull the substantially smooth section of thematerial against the vacuum table (operation 1804). Afterwards, theprocess terminates. In operation 1804, a vacuum may be applied to eachsegment in the group of segments in the vacuum table immediately, ornearly immediately, after the smoothing device moves across the surfaceof the material corresponding to the segment. In this manner, segmentsof the vacuum table are activated, one at a time, to progressively pulldown already smooth sections of the material. The vacuum may be pulledthrough a porous material over the group of segments such that thesubstantially smooth section of the material is pulled against theporous material of the vacuum table.

Turning to FIG. 19, an illustration of a process for smoothing amaterial having wrinkles is depicted in accordance with an illustrativeembodiment. The process illustrated in FIG. 19 may be implemented byautomated smoothing system 1730 shown in FIG. 17. The process shown inFIG. 19 may be implemented using automated smoothing system 102 shown inFIGS. 1-16 to smooth material 103 having wrinkles 104.

The process begins by unrolling a desired amount of material onto avacuum table (operation 1900). The material may have wrinkles or otherimperfections after being rolled out on the vacuum table. The materialmay be material 103 of FIGS. 1-16.

Next, the process clamps the material to the vacuum table using aclamping system (operation 1902). In some illustrative examples, thematerial may be clamped to the vacuum table using clamping system 204 ofFIG. 2.

Thereafter, the process translates the smoothing device across thesurface of the material using a first movement system (operation 1904).The material is held against the vacuum table using the clamping systemwhile the smoothing device moves across the surface of the material toremove the wrinkles from the material. In some examples, a brush systemmay translate across the surface of the material from the clamped edgeof the material to the free edge of the material, removing wrinklesalong the way. In other words, in these examples, a brush system maytranslate across the surface of the material from a first edge of thematerial to a second edge of the material using a first movement system.

The process rotates a cylindrical brush in the smoothing device using asecond movement system as the smoothing device translates across thesurface of the material (operation 1906). Concurrently with operation1904 and operation 1906, the process identifies a position of thesmoothing device relative to the surface of the material using a sensorsystem (operation 1908).

The process then activates different segments in the group of segmentsin the vacuum table based on the position of the smoothing device(operation 1910). In this illustrative example, each segment isactivated immediately after the smoothing device moves across thesurface over that particular segment, however, other timing intervalsare possible.

By activating the different segments, the material the smoothing devicehas translated across may be pulled against the vacuum table. In someillustrative examples, activating the different segments may be done bypulling a vacuum. Further, in some illustrative examples, a vacuum maybe pulled through a porous material over the different segments suchthat the material the smoothing device has translated across is pulledagainst the porous material of the vacuum table.

Operations 1906-1910 remove wrinkles and other imperfections from thematerial to form a substantially smooth section of the material.Optionally, ionized air may be blown on the wrinkled material using ablower as the wrinkled material is smoothed. In some examples, ionizedair may be blown on the material after being smoothed.

The process may identify a level of wrinkle removal completed by thesmoothing device (operation 1912). For instance, a camera system orother vision system may use shadows cast on the material by theseimperfections to determine the extent to which wrinkles have beenremoved from the material.

A determination is then made as to whether wrinkles have been removed asdesired (operation 1914). If wrinkles have been removed as desired, theprocess cuts the substantially smooth section of the material to form asubstantially smooth sheet of the material having desired dimensions(operation 1916). Thereafter, the process transports the substantiallysmooth sheet of the material using a transport device (operation 1918).Afterwards, the process terminates. The substantially smooth sheet ofthe material may be transported to a different location for furtherprocessing or for use in forming a structure.

Returning to operation 1914, if wrinkles have not been removed asdesired, the process returns to operation 1904, as described above. Insome cases, after operation 1918, the process may return to operation1900 to begin preparing another sheet of material. In this manner, theprocess described in FIG. 19 provides consistent, automated smoothingfor wrinkled material.

In FIG. 20, an illustration of a flowchart of a process for transportinga substantially smooth sheet of material is depicted in accordance withan illustrative embodiment. The process illustrated in FIG. 20 may beimplemented during operation 1918 in FIG. 19 using various tools inmanufacturing system 1706 in FIG. 17.

The process begins by moving a transport device above the surface of thesubstantially smooth sheet of material (operation 2000). Next, theprocess applies a force against the surface of the substantially smoothsheet of material using the transport device (operation 2002). Forinstance, a transport device may press its end effector against thesurface of the smooth sheet of material.

Thereafter, a vacuum is applied to the surface of the substantiallysmooth sheet of material to pull the substantially smooth sheet ofmaterial against the transport device (operation 2004). In operation2004, a separate vacuum system associated with the transport device maybe used to temporarily attach the substantially smooth sheet of materialto the end effector of the transport device.

The process then transfers the substantially smooth sheet of materialusing a reverse blow off process to push the substantially smooth sheetof material away from a vacuum table (operation 2006). Afterwards theprocess terminates. In operation 2006, a puff of air may be used toseparate the substantially smooth sheet of material from the vacuumtable.

Turning next to FIG. 21, an illustration of a flowchart of a process fordesigning a structure is depicted in accordance with an illustrativeembodiment. The process illustrated in FIG. 21 may be used to generate adesign for manufacturing structure 1704 shown in FIG. 17. The process inFIG. 21 may be implemented in designer 1708 in FIG. 17.

The process begins by receiving input for designing a structure(operation 2100). This input may include, for example, a number ofdesired performance parameters and other suitable types of input.

Thereafter, the process identifies a number of desired performanceparameters for the structure (operation 2102). The process then selectsmaterials for sheets of material used to form the structure (operation2104).

The process also identifies dimensions for sheets of material used toform the structure (operation 2106). Next, the process selects a desiredsmoothness for each of the sheets of material (operation 2108). Theprocess then generates the design for the structure from theidentifications and selections (operation 2110), with the processterminating thereafter. This design may be used to generate instructionsfor an automated smoothing system to smooth sheets of material used toform the structure.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatuses and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent at least one of module, a segment, a function, ora portion a combination thereof of an operation or step.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be executed substantially concurrently, or the blocks maysometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added in addition tothe illustrated blocks in a flowchart or block diagram.

Thus, the illustrative embodiments provide an automated system andmethod for smoothing material 103 having wrinkles 104. Material 103 ispositioned on vacuum table 200. Vacuum table 200 has group of segments300. Smoothing device 202 is moved across surface 107 of material 103 toform substantially smooth section 1302 of material 103. A vacuum isprogressively applied to a portion of group of segments 300 in vacuumtable 200 corresponding to substantially smooth section 1302 of material103 to pull substantially smooth section 1302 of material 103 againstvacuum table 200.

With the use of an illustrative embodiment, the need for human operatorsto manually flatten wrinkled material may be reduced or eliminated. As aresult, labor hours are reduced and significant cost savings may berealized.

Moreover, automated smoothing processes conducted in accordance with anillustrative embodiment save time and smooth wrinkled material morequickly than some currently used methods. Because the smoothing processis faster, manufacturing processes using the smoothed material may beimplemented more quickly, resulting in a higher production rate within afacility.

The progressive operation of the vacuum table works to eliminate theproblems associated with creases in the material caused by the materialjust sitting on a table with a vacuum. The progressive operation of thevacuum table also minimizes issues associated with stretching thematerial as it is pulled to the table. The wrinkles in the material arepulled out as the rotating brush advances and the vacuum sections turnon to hold the material in a flat condition. In this manner, anautomated smoothing system in accordance with an illustrative embodimentmay be adapted for various types of material and thicknesses ofmaterial. This adaptation may occur under the coordinated control of asingle system controller that dynamically adjusts various componentswithin the automated smoothing system to smooth the wrinkled sheet ofmaterial as desired.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different features as compared to otherdesirable embodiments. The embodiment or embodiments selected are chosenand described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. An apparatus comprising: a vacuum table having agroup of segments, wherein a material having wrinkles is positioned onthe vacuum table; a smoothing device that moves across a surface of thematerial to form a substantially smooth section of the material; and avacuum system that progressively applies a vacuum to a portion of thegroup of segments in the vacuum table to pull the substantially smoothsection of the material against the vacuum table.
 2. The apparatus ofclaim 1 further comprising: a clamping system that clamps the materialto the vacuum table and holds the material against the vacuum tablewhile the smoothing device moves across the surface of the material toremove the wrinkles from the material.
 3. The apparatus of claim 1further comprising: a sensor system that identifies a position of thesmoothing device relative to the surface of the material.
 4. Theapparatus of claim 3, further comprising: a controller that activatesdifferent segments in the group of segments in the vacuum table based onthe position of the smoothing device.
 5. The apparatus of claim 1further comprising: a movement system that moves the smoothing deviceacross the surface of the material, wherein the vacuum is applied to asegment in the group of segments in the vacuum table immediately afterthe smoothing device moves across the surface of the materialcorresponding to the segment.
 6. The apparatus of claim 1, furthercomprising: a first movement system that retracts the smoothing deviceafter the substantially smooth section is formed.
 7. The apparatus ofclaim 1, wherein the smoothing device comprises a cylindrical brushhaving helically wound bristles.
 8. The apparatus of claim 7, furthercomprising: a second movement system that rotates the cylindrical brushas the cylindrical brush translates across the surface of the material.9. The apparatus of claim 1, further comprising: a transport device thattransports the substantially smooth section.
 10. The apparatus of claim1, further comprising: a substantially smooth sheet formed by cuttingthe substantially smooth section of the material to desired dimensions.11. The apparatus of claim 10, wherein the apparatus transfers thesubstantially smooth sheet using a reverse blow off process to push thesubstantially smooth sheet away from the vacuum table.
 12. The apparatusof claim 10, further comprising: a transport device that transports thesubstantially smooth sheet.
 13. The apparatus of claim 1, furthercomprising: a blower device for blowing ionized air on the materialusing a blower.
 14. The apparatus of claim 1, further comprising: avision system that identifies a level of wrinkle removal.
 15. Anapparatus comprising: a vacuum table having a group of segments, whereina material having wrinkles is positioned on the vacuum table; asmoothing device that moves across a surface of the material to form asubstantially smooth section of the material; a vacuum system thatprogressively applies a vacuum to a portion of the group of segments inthe vacuum table to pull the substantially smooth section of thematerial against the vacuum table; a clamping system that clamps thematerial to the vacuum table and holds the material against the vacuumtable while the smoothing device moves across the surface of thematerial to remove the wrinkles from the material. a sensor system thatidentifies a position of the smoothing device relative to the surface ofthe material; and a controller that activates different segments in thegroup of segments in the vacuum table based on the position of thesmoothing device.
 16. The apparatus of claim 15 further comprising: avision system that identifies a level of wrinkle removal in thematerial.
 17. The apparatus of claim 15 further comprising: a movementsystem that moves the smoothing device across the surface of thematerial, wherein the vacuum is applied to a segment in the group ofsegments in the vacuum table immediately after the smoothing devicemoves across the surface of the material corresponding to the segment.18. The apparatus of claim 15, further comprising: a blower device forblowing ionized air on the material using a blower.
 19. The apparatus ofclaim 15, further comprising: a substantially smooth sheet formed bycutting the substantially smooth section of the material to desireddimensions.
 20. The apparatus of claim 19, wherein the apparatustransfers the substantially smooth sheet using a reverse blow offprocess to push the substantially smooth sheet away from the vacuumtable.